Insulated bag

ABSTRACT

An insulated bag assembly includes an insulated bag, the insulated bag comprising a pair of opposing main panels, the main panels defined in an insulated blank, the insulated blank comprising an insulation batt, a first sheet, and a second sheet, the insulation batt encapsulated in a blank cavity defined between the first sheet and the second sheet, a blank border extending around a perimeter of the insulated blank, the blank border defined by a perimeter portion of the first sheet being in facing engagement with a perimeter portion of the second sheet, the blank border encompassing the blank cavity and defining an insulated portion of the insulated blank, the insulated bag defining a bag cavity with a bag opening; and an insulated panel, the insulated panel positioned within the bag cavity, the insulated panel forming a seal with the insulated bag.

JOINT RESEARCH AGREEMENT

The subject matter disclosed was developed and the claimed invention wasmade by, or on behalf of, one or more parties to a joint researchagreement between MP Global Products LLC of Norfolk, Nebr. and PrattRetail Specialties, LLC of Conyers, Ga., that was in effect on or beforethe effective filing date of the claimed invention, and the claimedinvention was made as a result of activities undertaken within the scopeof the joint research agreement.

TECHNICAL FIELD

This disclosure relates to packaging. More specifically, this disclosurerelates to an insulated bag.

BACKGROUND

Packaging perishable or temperature sensitive contents for storage orshipping can pose challenges. The contents can spoil, destabilize,freeze, melt, or evaporate during storage or shipping if the temperatureof the contents is not maintained or the packaging is not protected fromhot or cold environmental conditions. Contents such as food,pharmaceuticals, electronics, or other temperature sensitive items canbe damaged if exposed to temperature extremes. Many insulated packagesare bulky and difficult to store prior to use. Additionally, manyinsulated packages cannot be recycled and are often disposed of inlandfills.

SUMMARY

It is to be understood that this summary is not an extensive overview ofthe disclosure. This summary is exemplary and not restrictive, and it isintended to neither identify key or critical elements of the disclosurenor delineate the scope thereof. The sole purpose of this summary is toexplain and exemplify certain concepts of the disclosure as anintroduction to the following complete and extensive detaileddescription.

Disclosed is an insulated bag assembly comprising an insulated bag, theinsulated bag comprising a pair of opposing main panels, the main panelsdefined in an insulated blank, the insulated blank comprising aninsulation batt, a first sheet, and a second sheet, the insulation battencapsulated in a blank cavity defined between the first sheet and thesecond sheet, a blank border extending around a perimeter of theinsulated blank, the blank border defined by a perimeter portion of thefirst sheet being in facing engagement with a perimeter portion of thesecond sheet, the blank border encompassing the blank cavity anddefining an insulated portion of the insulated blank, the insulated bagdefining a top end and a bottom end, the top end distal from the bottomend, the insulated bag defining a bag cavity with a bag openingpositioned at the top end; and an insulated panel, the insulated panelpositioned within the bag cavity, the insulated panel forming a sealwith the insulated bag.

Also disclosed is an insulated bag comprising a pair of opposing mainpanels, the insulated bag defining a bag cavity within the insulatedbag, the insulated bag defining a bag opening to the bag cavity, the bagopening disposed at a top end of the insulated bag; the main panelsdefined in an insulated blank, the insulated blank comprising a firstsheet; a second sheet, the second sheet attached to the first sheet by ablank border, the blank border extending around a perimeter of theinsulated blank, the blank border enclosing a blank cavity definedbetween the first sheet and the second sheet; and an insulation battpositioned within the blank cavity.

Also disclosed a method for assembling an insulated bag includingfolding a first main panel of a pair of opposing main panels relative toa first side panel of a pair of opposing side panels about a main creaseline, the main panels, the side panels, and the main crease line definedin an insulated blank, the insulated blank including an insulation batt,a first sheet, and a second sheet, the insulation batt encapsulated in ablank cavity defined between the first sheet and the second sheet, ablank border extending around a perimeter of the insulated blank, theblank border defined by a perimeter portion of the first sheet being infacing engagement with a perimeter portion of the second sheet, theblank border encompassing the blank cavity and defining an insulatedportion of the insulated blank, the insulated blank defining a first endand a second end, the first end disposed opposite from the second end;attaching the first end to the second end; and forming a bottom panel ofthe insulated bag by folding a portion of the bottom panel relative tothe main panel about a bottom crease line, the bottom panel and thebottom crease line further defined by the insulated blank.

Various implementations described in the present disclosure may includeadditional systems, methods, features, and advantages, which may notnecessarily be expressly disclosed herein but will be apparent to one ofordinary skill in the art upon examination of the following detaileddescription and accompanying drawings. It is intended that all suchsystems, methods, features, and advantages be included within thepresent disclosure and protected by the accompanying claims. Thefeatures and advantages of such implementations may be realized andobtained by means of the systems, methods, features particularly pointedout in the appended claims. These and other features will become morefully apparent from the following description and appended claims, ormay be learned by the practice of such exemplary implementations as setforth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and components of the following figures are illustrated toemphasize the general principles of the present disclosure. The drawingsare not necessarily drawn to scale. Corresponding features andcomponents throughout the figures may be designated by matchingreference characters for the sake of consistency and clarity.

FIG. 1 is a perspective view of an insulated bag assembly in accordancewith one aspect of the disclosure.

FIG. 2A is a cross-sectional view of an insulated bag of the insulatedbag assembly of FIG. 1 taken along line 2-2 in FIG. 1.

FIG. 2B is a detail view of a main seam of FIG. 2A taken from Detail 2Bin FIG. 2A.

FIG. 3A is a cross-sectional view of another aspect of the insulated bagassembly taken along line 3-3 in FIG. 1.

FIG. 3B is a detail view of the insulated bag assembly of FIG. 3A takenfrom Detail 3B in FIG. 3A.

FIG. 4A is a perspective view of an insulated blank in apartially-folded configuration.

FIG. 4B is a perspective view of the insulated bag of FIG. 1 in apartially assembled position.

FIG. 4C is a perspective view of the insulated bag of FIG. 1 in apartially assembled position.

FIG. 4D is a perspective view of the insulated bag of FIG. 1 in anassembled position.

FIG. 4E is a perspective view of another aspect of the insulated bag ina sealed configuration.

FIG. 5A is a perspective view of another aspect of the insulated bagcomprising a pair of main handles.

FIG. 5B is a perspective view of another aspect of the insulated bagcomprising a pair of side handles.

FIG. 5C is a perspective view of another aspect of the insulated bagcomprising a seam handle.

FIG. 5D is a perspective view of another aspect of the insulated bagsealed by a roll.

FIG. 5E is a perspective view of another aspect of the insulated bagcomprising a plurality of flaps.

FIG. 5F is a perspective view of another aspect of the insulated bagsealed by a fold.

FIG. 6 is a perspective view of a method of manufacturing for aninsulated blank.

FIG. 7A is a top view of a blank sheet.

FIG. 7B is a top view of one aspect of an insulation batt.

FIG. 7C is a top view of another aspect of the insulation battcomprising a pair of bottom subpanel extensions.

FIG. 7D is a top view of another aspect of the insulation batt defininga pair of wing holes.

FIG. 8 is a top view of a double blank sheet.

FIG. 9 is a perspective view of a method of assembling one aspect of theinsulated bag comprising flaps.

DETAILED DESCRIPTION

The present disclosure can be understood more readily by reference tothe following detailed description, examples, drawings, and claims, andthe previous and following description. However, before the presentdevices, systems, and/or methods are disclosed and described, it is tobe understood that this disclosure is not limited to the specificdevices, systems, and/or methods disclosed unless otherwise specified,and, as such, can, of course, vary. It is also to be understood that theterminology used herein is for the purpose of describing particularaspects only and is not intended to be limiting.

The following description is provided as an enabling teaching of thepresent devices, systems, and/or methods in its best, currently knownaspect. To this end, those skilled in the relevant art will recognizeand appreciate that many changes can be made to the various aspects ofthe present devices, systems, and/or methods described herein, whilestill obtaining the beneficial results of the present disclosure. Itwill also be apparent that some of the desired benefits of the presentdisclosure can be obtained by selecting some of the features of thepresent disclosure without utilizing other features. Accordingly, thosewho work in the art will recognize that many modifications andadaptations to the present disclosure are possible and can even bedesirable in certain circumstances and are a part of the presentdisclosure. Thus, the following description is provided as illustrativeof the principles of the present disclosure and not in limitationthereof.

As used throughout, the singular forms “a,” “an” and “the” includeplural referents unless the context clearly dictates otherwise. Thus,for example, reference to “an element” can include two or more suchelements unless the context indicates otherwise.

Ranges can be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, another aspect includes from the one particular value and/orto the other particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another aspect. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint.

For purposes of the current disclosure, a material property or dimensionmeasuring about X or substantially X on a particular measurement scalemeasures within a range between X plus an industry-standard uppertolerance for the specified measurement and X minus an industry-standardlower tolerance for the specified measurement. Because tolerances canvary between different materials, processes and between differentmodels, the tolerance for a particular measurement of a particularcomponent can fall within a range of tolerances.

As used herein, the terms “optional” or “optionally” mean that thesubsequently described event or circumstance can or cannot occur, andthat the description includes instances where said event or circumstanceoccurs and instances where it does not.

The word “or” as used herein means any one member of a particular listand also includes any combination of members of that list. Further, oneshould note that conditional language, such as, among others, “can,”“could,” “might,” or “may,” unless specifically stated otherwise, orotherwise understood within the context as used, is generally intendedto convey that certain aspects include, while other aspects do notinclude, certain features, elements and/or steps. Thus, such conditionallanguage is not generally intended to imply that features, elementsand/or steps are in any way required for one or more particular aspectsor that one or more particular aspects necessarily include logic fordeciding, with or without user input or prompting, whether thesefeatures, elements and/or steps are included or are to be performed inany particular aspect.

Disclosed are components that can be used to perform the disclosedmethods and systems. These and other components are disclosed herein,and it is understood that when combinations, subsets, interactions,groups, etc. of these components are disclosed that while specificreference of each various individual and collective combinations andpermutation of these may not be explicitly disclosed, each isspecifically contemplated and described herein, for all methods andsystems. This applies to all aspects of this application including, butnot limited to, steps in disclosed methods. Thus, if there are a varietyof additional steps that can be performed it is understood that each ofthese additional steps can be performed with any specific aspect orcombination of aspects of the disclosed methods.

In one aspect, disclosed is an insulated bag assembly and associatedmethods, systems, devices, and various apparatus. The insulated bagassembly can comprise an insulated bag and an insulated blank. It wouldbe understood by one of skill in the art that the disclosed insulatedbag assembly is described in but a few exemplary aspects among many. Noparticular terminology or description should be considered limiting onthe disclosure or the scope of any claims issuing therefrom.

FIG. 1 is a perspective view of one aspect of an insulated bag assembly100. The insulated bag assembly 100 can comprise an insulated bag 110and an insulated panel 190. In the present aspect, the insulated bag 110can be assembled from a single insulated blank 111 as shown in FIGS.4A-D; however in other aspects, the insulated bag 110 can be assembledfrom multiple insulated blanks 111. The insulated bag 110 can comprise apair of opposing main panels 112, a pair of opposing side panels 114,and a bottom panel 201 (shown in FIG. 2A). The main panels 112, the sidepanels 114, and the bottom panel 201 can be defined in the insulatedblank 111. The main panels 112 and the side panels 114 can define a bagbody 101. The bag body 101 can define a substantially rectangularcross-sectional shape; however in other embodiments, the main panels 112and the side panels 114 can further define a square or can define adifferent shape as desired. The rectangular cross-sectional shape candefine four corners 118A-D, each defined at a different intersection ofa one of the main panels 112 and a one of the side panels 114.

In the present aspect, three of the corners 118A-C can define maincrease lines 122. At each of the main crease lines 122, a one of themain panels 112 can fold relative to one of the side panels 114. Thefourth corner 118D can define a main seam 120 at which a first end 124of the insulated blank 111 can be attached to a second end 125 of theinsulated blank 111. When the insulated blank 111 is laid flat in anunfolded configuration the first end 124 of the insulated blank 111 canbe defined opposite from the second end 125. In the present aspect, aone of the main panels 112 can be positioned proximate the first end124, and a one of the side panels 114 can be positioned proximate thesecond end 125. In other aspects, the main seam 120 can be definedextending through one of the main panels 112 or side panels 114 insteadof at any of the corner 118. In some aspects, the insulated bag 110 candefine more than one main seam 120.

Each side panel 114 can comprise a pair of side subpanels 144. Each pairof side subpanels 144 can be defined by a side crease line 116 which cansubstantially bisect the respective side panel 114. In some aspects, oneof the side crease lines 116 can be replaced by the main seam 120. Thepair of side subpanels 144 of each side panel 114 can fold relative toone another about the respective side crease line 116.

As shown in FIG. 2A, the insulated blank 111 can comprise a first sheet132, a second sheet 134, and an insulation batt 220. The insulation batt220 can be a single, continuous piece of insulation extending throughthe main panels 112, the side panels 114, and the bottom panel 201. Insome aspects, the single, continuous piece of insulation may only extendthrough the main panels 112 and the side panels 114 such that the bottompanel is uninsulated or comprises a separate insulation batt. Theinsulation batt 220 can be positioned between the first sheet 132 andthe second sheet 134 in a blank cavity 221 defined between the sheets132,134 of the insulated blank 111. In the present aspect, theinsulation batt 220, the first sheet 132, and the second sheet 134 caneach be continuous from the first end 124 to the second end 125 of theinsulated blank 111. The ends 124,125 can be attached by the main seam120 at the corner 118D. In some aspects, the insulation batt 220 candefine one or more grooves 760 (as shown in FIG. 7B). Each groove 760can be positioned in alignment with a one of the crease lines 116,122.

As shown in FIG. 4A, a blank border 440 can extend around a perimeter ofthe insulated blank 111. The blank cavity 221 can be enclosed by theblank border 440. In some aspects, the blank border 440 can seal theblank cavity 221 from an outside environment. The blank border 440 canbe formed by attaching together in facing engagement a perimeter portionof the first sheet 132 and a perimeter portion of the second sheet 134without the insulation batt 220 positioned between the respectiveportions. The blank border 440 can be uninsulated. The blank border 440can comprise a top border 137 (shown in FIG. 1), a first end border 224,and a second end border 225 (shown in FIG. 2B), and a bottom border 305(shown in FIG. 3A). The process is further described below with respectto FIG. 6.

The first sheet 132 can define an inner surface 133, and the secondsheet 134 can define an outer surface 135 of the insulated bag 110. Theinsulated bag 110 can define a top end 126 and a bottom end 128 distalfrom the top end 126. The main seam 120 can extend from the top end 126to the bottom end 128. The inner surface 133 can define a bag cavity 130with a bag opening 131 positioned at the top end 126. In the presentembodiment, the top border 137 of the blank border 440 can be positionedat the top end 126 of the insulated bag 110 extending around the bagopening 131. In the aspect shown, the top border 137 can be extendedrelative to other portions of the blank border 440, and the top border137 can define an uninsulated bag lip 136. In other aspects, the topborder 137 can extend a similar distance as other portions of the blankborder 440. In some aspects, the insulated bag 110 can define a taperextending towards the top border 137, and the taper can define a bagbeveled edge 152 proximate the bag opening 131. In the present aspect,the blank border 440 can extend around the bag opening 131, extend fromthe top end 126 to the bottom end 128, and extend across the bottompanel 201.

In the present aspect, the insulated bag 110 can further comprise a pairof wings 150 which can be secured by a tape strip 160. In other aspects,the wings 150 can be secured by an adhesive or other suitable method.The wings 150 can be formed in one aspect of a method of assembly asshown in FIGS. 4A-D. In the present aspect, the tape strip 160 cansecure each wing 150 to the outer surface 135 of a one of the sidepanels 114. In some aspects, the tape strip 160 can extend from one sidepanel 114, across the bottom panel 201 to the opposite side panel 114,and secure both wings 150. In such aspects, the tape strip 160 canreinforce the bottom panel 201 and a bottom seam 203 (shown in FIG. 2A).In other aspects, each wing 150 can be secured by a separate tape strip160. In some aspects, the insulated bag 110 may not comprise the wings150.

The insulated panel 190 of the insulated bag assembly 100 can define apanel insulated portion 191 and a panel border 192. A taper between thepanel insulated portion 191 and the panel border 192 can define a panelbeveled edge 193. The insulated panel 190 can be shaped and sizedcomplimentary to the bag opening 131. In some aspects, the insulatedpanel 190 can be configured to cover the bag opening 131, and the panelbeveled edge 193 can cooperate with the bag beveled edge 152 to form aseal as shown in FIG. 3A.

FIG. 2A depicts a cross-sectional view of the insulated bag 110 of FIG.1 taken across line 2-2 as shown in FIG. 1. The view of FIG. 2A facesdownwards towards the bottom end 128 of the insulated bag 110. Thebottom panel 201 can be positioned at the bottom end 128. The bottompanel 201 can comprise two bottom subpanels 202 joined by a bottom seam203. As shown in FIG. 3A the bottom seam 203 can be formed by attachingtogether opposing portions of the bottom border 305 of the blank border440, and each opposing portion can extend across the bottom panel 201from a first one of the side crease lines 116 to a second one of theside crease lines 116. In the present aspect, the bottom seam 203 canextend from one side panel 114 to the other side panel 114; in otheraspects, the bottom seam 203 can extend from one main panel 112 to theother main panel 112. In some aspects, the bottom panel 201 can define aplurality of bottom seams 203. In other aspects, the bottom panel 201may not comprise bottom subpanels 202 and instead can comprises a singlepanel, and the bottom seam 203 can be positioned at an intersectionbetween the bottom panel 201 and a one of the main panels 112 or sidepanels 114. In other aspects, the bottom panel 201 may be comprised of aplurality of flaps 905A,B (as shown in FIG. 9) and may not define thebottom seam 203.

FIG. 2B is a detailed view of the main seam 120 shown in FIG. 2A. Asshown, the first sheet 132 and the second sheet 134 can each extendbeyond the insulation batt 220 at both the first end 124 and the secondend 125 of the insulated blank 111. The perimeter portions of the firstsheet 132 and the second sheet 134 extending beyond the insulation batt220 at the first end 124 can be attached together to form the first endborder 224. The first end border 224 can be a two-ply seam formed byoverlapping portions of the first sheet 132 and the second sheet 134.Similarly, portions of the first sheet 132 and the second sheet 134extending beyond the insulation batt 220 at the second end 125 can beattached together to form the second end border 225. The second endborder 225 can be a two-ply seam formed by overlapping portions of thefirst sheet 132 and the second sheet 134. The main seam 120 can be afour-ply seam formed by overlapping portions of the first end border 224and the second end border 225. The first end border 224 and the secondend border 225 can each be defined by the blank border 440.

In the aspect shown, the first end border 224 and the second end border225 can each be formed by attaching the first sheet 132 and the secondsheet 134 together in facing engagement with a first adhesive 226. Thefirst end border 224 and the second end border 225 can each be definedby the continuous blank border 440, and the first adhesive 226 canextend completely through the blank border 440. The first adhesive 226can be a glue, cement, cohesive, epoxy, double-sided tape, or otheradhesive. In some aspects, the first adhesive 226 can be a cohesivewherein the areas treated with the cohesive are configured toselectively adhere only to other areas treated with the cohesive. Insuch an embodiment, surfaces of the first sheet 132 and the second sheet134 facing one another can each be selectively or entirely treated withcohesive, and only the treated areas positioned in facing engagement mayadhere to one another. In some aspects, the first sheet 132 and thesecond sheet 134 can be attached through other methods such as taping,stitching, stapling, hemming, or other suitable attachment mechanisms.

The first end border 224 and the second end border 225 can be attachedtogether to form the main seam 120. The first end border 224 can beattached to the second end border 225 with a second adhesive 227. Thesecond adhesive 227 can be the same as the first adhesive 226, or thesecond adhesive 227 can be a different type of adhesive. The secondadhesive 227 can be a glue, cement, cohesive, epoxy, double-sided tape,or other adhesive. In other aspects, the first end border 224 and thesecond end border 225 can be attached through other methods such astaping, stitching, stapling, hemming, or other suitable attachmentmechanisms. In the present aspect, the main seam 120 can be a lap seamin which the first end border 224 and the second end border 225 overlapone another. In other aspects, the main seam can be a different type ofseam such as a plain seam, or any other type of suitable seam.

FIG. 3A is cross-sectional view of another aspect of the insulated bagassembly 100. In the aspect shown, the insulated bag assembly 100 cancomprise a plurality of insulated panels 190A-D. The insulated panels190A-D can be the same as one another; however, in other aspects, theinsulated panels 190A-D can vary in shape or size. In the presentaspect, the insulated panels 190B-D can be sized slightly smaller thanthe insulated panel 190A in order to facilitate insertion into the bagcavity 130. The insulated bag assembly 100 can also comprise more orless insulated panels 190 than shown in FIG. 3A. Each insulated panel190 can comprise a first blank sheet 332, a second blank sheet 334, andan insulation batt 391. A construction of the insulated panel 190 can besimilar to a construction of the insulated blank 111. The first blanksheet 332 can be attached to the second blank sheet 334 around aperimeter of the insulated panel 190 which forms the panel border 192.The panel border 192 can enclose a panel cavity 321 between the firstblank sheet 332 and the second blank sheet 334. The insulation batt 391can be encapsulated within the panel cavity 321. A portion of theinsulated panel 190 positioned inwards from the panel border 192 candefine the panel insulated portion 191. In some aspects, a one of theinsulated panels 190 can be attached to the insulated bag 110. Forexample and without limitation, a portion of the panel border 192 can beattached to a portion of the uninsulated bag lip 136 or the top border137 to form a hinged top panel (not shown).

The insulated panel 190B can be positioned within the bag cavity 130proximate the bag opening 131. Enclosing the bag cavity 130 with theinsulated panel 190B can create an insulated cavity 329. In the aspectshown, the panel beveled edge 193 can be positioned against the bagbeveled edge 152 to form the seal. The insulated panel 190C can bepositioned within the bag cavity 130 between the top end 126 and thebottom end 128 in order to partition the bag cavity 130 into twosubcavities 330A,B. The insulated panel 190B can form a seal with theinner surface 133. This configuration can be desirable in order topackage and store contents at different temperatures. For example andwithout limitation, the subcavity 330A can be used to store warmcontents while the subcavity 330B can be used to store cool contents. Inother aspects, the insulated panel 190B can rest upon contents of thesubcavity 330B.

In other aspects, the bag cavity 130 can be partitioned into more thantwo subcavities 330. In the present aspect, the insulated panels 190 areshown in a horizontal orientation partitioning the bag cavity 130top-to-bottom; however in other aspects, the insulated panels 190 can bepositioned in a vertical orientation which can partition the bag cavity130 side-to-side, front-to-back, or diagonally (not shown). In someaspects, the insulated bag assembly 100 can comprise any number ofinsulated panels 190 in both horizontal and vertical configurations.

In the present aspect, the insulated panel 190D can be positioned atopthe bottom panel 201 at the bottom end 128 of the insulated bag 110. Thebottom panel 201 can be insulated, and the insulated panel 190 can beplaced on top of the bottom panel 201. This configuration can provideadditional insulation at the bottom end 128 of the insulated bag 110.Additional insulation at the bottom end 128 can be desirable in order tominimize conduction of heat through the bottom end 128 of the insulatedbag 110, such as when the bottom end 128 of the insulated bag 110 isrested on a hot or cold environmental surface. In some aspects, theinsulation batts 391 can be thicker or thinner than the insulation batt220. In some aspects, the insulation batts 391 can be more or less densethan the insulation batt 220. In some applications, a more denseinsulation batt 391 or insulation batt 220 can be desirable, such aswhen the bag cavity 130 contains heavy contents. More dense insulationcan better resist compression which can degrade an insulation value ofthe batts 220,391.

In some aspects, the bottom panel 201 may not comprise insulation, andthe insulated panel 190D can be positioned atop the bottom panel 201 toinsulate the bottom end 128 of the insulated bag 110. This configurationcan be desirable for reasons such as ease of manufacturing. In someaspects in which the insulation batt 220 defines a greater thickness,such as over ¾″ thick, the insulation batt 220 can be difficult to bendabout a pair of bottom crease lines 441 (shown in FIG. 4A) defined atintersections between the main panels 112 and the bottom subpanels 202.Providing insulation at the bottom end 128 with the separate insulatedpanel 190D can simplify manufacturing and assembly of the insulated bag110 in some aspects.

As shown in FIG. 3B, the bottom seam 203 and the bottom border 305 canbe formed similar to the main seam 120; however, the bottom seam 203 canbe formed as a plain seam rather than as the lap seam of the main seam120. The bottom border 305 can be a two-ply seam formed by overlappingportions of the first sheet 132 and the second sheet 134. The bottomseam 203 can be a four-ply seam formed by overlapping portions ofopposing portions of the bottom border 305. In other aspects, the bottomseam 203 can be formed as the lap seam. In some aspects, the bottom seam203 can be covered and reinforced by the tape strip 160 (not shown). Thebottom border 305 can be formed by attaching the first sheet 132 and thesecond sheet 134 in facing engagement. In some aspects, the bottomborder 305 can be formed by attaching the first sheet 132 and the secondsheet 134 with a third adhesive 326 which can be a glue, cement,cohesive, epoxy, double-sided tape, or other adhesive. The thirdadhesive 326 can be the same as any of the first adhesive 226 or thesecond adhesive 227. In some aspects, the bottom border 305 can beattached together to form the bottom seam 203 by a fourth adhesive 327which can be a glue, cement, cohesive, epoxy, double-sided tape, orother adhesive. The fourth adhesive 327 can be the same as any of thefirst adhesive 226, the second adhesive 227, or the third adhesive 326.In other aspects, the bottom border 305 can be attached together throughother methods such as taping, stitching, stapling, hemming, or othersuitable attachment mechanisms.

FIGS. 4A-E show perspective views of an assembly process for one aspectof the insulated bag 110. FIG. 4A is a perspective view of a first step401 of the assembly process for one aspect of the insulated bag 110. Theinsulated blank 111 in a partially-folded configuration. A foldedconfiguration can be suitable for storage and transportation of theinsulated blank 111. The insulated blank 111 is shown folded across theside crease lines 116, and the main seam 120 and the bottom seam 203have not been formed. The first end 124 and the second end 125 arepositioned proximate to one another, but are not yet attached. Thebottom subpanels 202 are also shown proximate to one another, but arenot yet attached. The blank border 440 extends entirely around theperimeter of the insulated blank 111. The blank border 440 can be atwo-ply seam formed from overlapping portions of the first sheet 132 andthe second sheet 134. In the aspect shown, the top border 137 can be theuninsulated bag lip 136 which can extend outwards further than a one ofthe first end border 224, the second end border 225, or the bottomborder. However, in some aspects, the top border 137 can extend outwardsa distance equal to or less than the first end border 224, the secondend border 225, and the bottom borders 305.

FIG. 4B is a perspective view of a second step 402 of the assemblyprocess for one aspect of the insulated bag 110. In the second step 402,the insulated bag 110 is shown with the first end 124 and the second end125 joined together at the main seam 120. Opposing portions of thebottom border 305 have been attached to form the bottom seam 203. Thebottom panel 201 is partially folded across the bottom seam 203 and atthe bottom crease lines 441. The intersection between each wing 150 andeach side panel 114 can define a base wing crease line 412. A pair ofsides of each wing 150 can define a pair of side wing crease lines 410.The wings 150 can extend slightly outwards from the side panels 114.

In some aspects, the configuration of the insulated bag 110 shown inFIG. 4B can be used as a finished product, such as an insulated sack,without a flat bottom. In such aspects, the bag opening 131, the mainpanels 112, and the side panels 114 can define an ovular, lens,biconvex, or elliptical cross-sectional shape rather than asubstantially rectangular shape as shown. In such aspects, the maincrease lines 122 can be excluded from insulated bag 110 such that eachof the main panels 112 and the pair of adjacent side subpanels 144 canbe continuous without folds or crease lines partitioning the sidesubpanels 144 from the main panels 112. In such aspects handles (notshown) can be attached proximate the bag opening 131 to allow a user tocarry the insulated bag 110.

FIG. 4C is a perspective view of a third step 403 of the assemblyprocess for one aspect of the insulated bag 110. The third step 403shows the insulated bag 110 with the bottom panel 201 flattened acrossthe bottom seam 203. The wings 150 can extend outwards from theinsulated bag 110 substantially perpendicular to the side panels 114,though the wings 150 can be angled at other angles other thansubstantially perpendicular in other aspects. The wing 150 has beenfolded to an approximate 90-degree angle about the base wing crease line412.

FIG. 4D is a perspective view of a fourth step 404 of the assemblyprocess for one aspect of the insulated bag 110. The fourth step 404shows the wings 150 further folded about the base wing crease lines 412until each wing 150 can be positioned in facing engagement with theouter surface 135 of a one of the side panels 114. In this position, thewings 150 can be secured by the tape strip 160. The insulated bag 110has thus been assembled but remains in an open configuration. In someaspects, the insulated bag 110 can further comprise an adhesive strip460. In some aspects, the adhesive strip 460 can comprise an adhesivecovered by a backing strip. A user can remove the backing strip toexpose the adhesive. The adhesive can be used to attach portions of theinsulated bag 110 in order to seal the bag opening 131. In the aspectshown, the adhesive strip 460 can be disposed on the inner surface 133of the uninsulated bag lip 136; however in other aspects, the adhesivestrip 460 can be disposed in a different location such as the innersurface 133 or outer surface 135 of a one of the side panels 114 or themain panels 112. In some aspects, the insulated bag 110 can comprisemultiple adhesive strips 460.

FIG. 4E is a perspective view of another aspect of the insulated bag ina closed and sealed configuration. In an optional fifth step 405, twoopposing portions of the uninsulated bag lip 136 can be attachedtogether to seal the bag opening 131 and form a top seam 450. The topseam 450 can be formed by adhering the inner surfaces 133 of theuninsulated bag lip 136 together with the adhesive strip 460 shown inFIG. 4D. The insulated bag 110 can further comprise a pair of carryhandles 451. The carry handles 451 can be comprised of rope or paper orany other suitable material. The carry handles 451 can be attached by ahandle tape strip 452 for each carry handle 451 and which can secure thecarry handles 451 to the insulated bag 110. In the aspect shown, thecarry handles 451 can be secured to the outer surface 135 of theinsulated bag 110. FIG. 4E shows only one configuration for sealing orcarrying on aspect of the insulated bag 110 and should not be viewed aslimiting.

FIGS. 5A-F show perspective views of various aspects of the insulatedbag 110 depicting optional end-use configurations. The configurationsshown should not be viewed as comprehensive or limiting. Any of theaspects shown can comprise one or more insulated panels 190. FIG. 5A isa perspective view of one aspect of the insulated bag 110 comprising apair of main handles 502. The main handles 502 can be fixed to theopposing pair of main panels 112. The main handles 502 can be fixed tothe inner surface 133 as shown or to the outer surface 135 of the mainpanels 112 proximate the bag opening 131. The main handles 502 can beconfigured to carry the insulated bag 110 and its contents. In theaspect shown, the main handles 502 are not configured to seal the bagopening 131. In such aspects, it can be desirable to position theinsulated panel 190 proximate the bag opening 131 to further insulatethe bag cavity 130.

FIG. 5B depicts an aspect similar to FIG. 5A. FIG. 5B is a perspectiveview of one aspect of the insulated bag 110 comprising a pair of sidehandles 504. The pair of side handles 504 can be fixed to the sidepanels 114 instead of the main panels 112, on either the inner surface133 or the outer surface 135. The carry handles 451, the main handles502, and the side handles 504 can each comprise a material such aspaper, rope, plastic, or any other material. In some aspects, it can bedesirable for the carry handles 451, the main handles 502, and the sidehandles 504 to comprise biodegradable, compostable, repulpable, orrecyclable materials. In the aspects shown in FIGS. 5A and 5B, the topborder 137 of the blank border 440 is not extended; however, someaspects comprising main handles 502 or side handles 504 can define theextended uninsulated bag lip 136 as shown in FIG. 4E.

FIG. 5C is a perspective view of one aspect of the insulated bag 110comprising a seam handle 506. The aspect shown is similar to the aspectof FIG. 4E; however, the top seam 450 can be modified to comprise theseam handle 506. The seam handle 506 can be defined by the uninsulatedbag lip 136 or the top border 137. In some aspects, the seam handle 506can be formed by attaching opposing portions of the uninsulated bag lip136 together with an adhesive.

FIG. 5D is a perspective view of one aspect of the insulated bag 110sealed by a roll 508. In some aspects, opposing portions of theuninsulated bag lip 136 can be rolled together to form the roll 508. Inthe present aspect, the roll 508 can be secured with a tape strip 560attaching the roll 508 to the outer surface 135. In some aspects, theroll 508 can be secured by stapling the roll 508. In other aspects, theadhesive strip 460 (not shown) can be disposed on the outer surface 135proximate the top end 126. The adhesive strip 460 can be configured toadhere to the roll 508 to secure the roll 508 to the outer surface 135of the insulated bag 110.

FIG. 5E is a perspective view of one aspect of the insulated bag 110comprising a plurality of flaps 510. The flaps 510 can be positionedproximate the top end 126. In the aspect shown, the flaps 510 can bedefined by the uninsulated bag lip 136; however in other aspects, theflaps 510 can be insulated. In some aspects, the uninsulated bag lip 136can be cut at each of the corners 118A-D to define four separate flaps510. In the aspect shown, two flaps (not shown) connected to the sidepanels 114 can be underlying two flaps 510 connected to the main panels112. The main panels 112 can be sealed with the tape strip 560. In someaspects, the bottom end 128 and the bottom panel 201 can be similarlyconstructed, and the bottom panel 201 can comprise a plurality of flaps510.

In some aspects, the corners 118 may not be cut, and the portions of theuninsulated bag lip 136 proximate the sides can be folded inwards toform the flaps 510 connected to the main panels 112. The flaps 510 canthen be folded inwards and attached to one another. In some aspects, theflaps 510 can be defined by the main panels 112 and the side panels 114and can be insulated as shown in FIG. 9. In some aspects, one of theflaps 510 can comprise the adhesive strip 460 defined on the innersurface 133 or the outer surface 135 with can be configure to attach anoverlapping portion of the flaps 510. The configuration shown in FIG. 5Ecan be desirable, for example, in applications in which the insulatedbag 110 is to be positioned within another container, such as acardboard box, when shipping the insulated bag 110. The configurationprovides the insulated bag 110 with a shape of a rectangular prism whichcompliments a shape of many commonly available cardboard boxes. However;any of the aspects of insulated bags 110 shown can be positioned withinanother container or used for applications such as shipping of theinsulated bags 110.

FIG. 5F is a perspective view of one aspect of the insulated bag 110sealed by a fold 512. The opposing portions of the uninsulated bag lip136 can be positioned together in facing engagement, and the uninsulatedbag lip 136 can be folded over a one of the main panels 112 to form thefold 512. The fold 512 can seal the bag opening 131. In the aspectshown, the fold 512 can be secured to the outer surface 135 with thetape strip 560. In some aspects, a portion of the outer surface 135 candefine the adhesive strip 460 configured to secure the fold 512.

FIG. 6 a perspective view of a method of manufacturing for an insulatedblank 610. The method can apply to the manufacture of either theinsulated blank 111, the insulated panels 190, or any other insulatedblank, and the insulated blank 610 can be the insulated blank 111 or theinsulated panel 190. In a step 601, an insulation batt 620 can bepositioned between a first sheet 632 and a second sheet 634. The firstsheet 632 and the second sheet 634 can be sized and shaped complimentaryto each other; however in some aspects, the sheets 632,634 can differ insize and shape. The insulated blank 610, the insulation batt 620, andthe sheets 632,634 can each be flat and substantially planar beforeassembly.

The first sheet 632 can define a first outer edge 652, and portions ofthe first sheet 632 proximate the first outer edge 652 can define afirst perimeter portion 642. The second sheet 634 can define a secondouter edge 654, and portions of the second sheet 634 proximate thesecond outer edge 654 can define a second perimeter portion 644. Thesheets 632,634 can be sized to overhang the insulation batt 620 on allsides with the first perimeter portion 642 and the second perimeterportion 644 extending beyond the insulation batt 620. The firstperimeter portion 642 can encompass a first interior portion 636 of thefirst sheet 632, and the second perimeter portion 644 can encompass asecond interior portion 638 of the second sheet 634. The interiorportions 636,638 can be sized and shaped complimentary to the insulationbatt 620.

Surfaces of the sheets 632,634 facing one another can be treated in orwith a fifth adhesive 630 such as a cohesive. In various aspects, theadhesive can be a glue, epoxy, cement, double-sided tape, or othersuitable adhesive. In some aspects, the fifth adhesive 630 can be thesame as any of the first adhesive 226, the second adhesive 227, thethird adhesive 326, or the fourth adhesive 327. The surfaces can beentirely treated with the fifth adhesive 630 or selectively treated withthe fifth adhesive 630. In the aspect shown, the perimeter portions642,644 can be selectively treated with the fifth adhesive 630. In someaspects, the insulation batt 620 can also be adhered to the interiorportions 636,638 of the sheets 632,634.

In a step 602, the sheets 632,634 can be aligned and positioned infacing engagement wherein the first perimeter portion 642 can beattached to the second perimeter portion 644 by the fifth adhesive 630.The insulation batt 620 can be aligned between the interior portions636,638. Attaching the perimeter portions 642,644 can form a borderportion 660 of the insulated blank 610. The border portion 660 can sealthe insulation batt 620 within a blank cavity 670 defined between theinterior portions 636,638 of the sheets 632,634, respectively. Portionsof the insulated blank 610 containing the insulation batt 620 can defineinsulated portions 661. In some aspects, the insulation batt 620 can bealigned off-center from the sheets 632,634 wherein the border portion660 can extend outwards further in some areas than others. Off-centeralignment can form features such as the uninsulated bag lip 136 where insome aspects, the top border 137 of the insulated blank 111 can beextended proximate the top end 126. Off-center alignment can alsoprovide for aspects wherein the bottom panel 201 can be uninsulated anddefined by the border portion 660 rather than the insulated portion 661.

In a step 603, the first perimeter portion 642 has been fully attachedto the second perimeter portion 644, thereby forming the completedborder portion 660. Manufacturing of the insulated blank 610 is thuscompleted; however in some aspects, the method can comprise additionalsteps such as cutting slots into the border portion 660 as shown in FIG.9. The border portion 660 can fully encapsulate the blank cavity 670;however in some aspects, the insulation batt 620 may not be fullyencapsulated. In some aspects, the insulation batt 620 can define acomplex shape which can comprise curves, notches, cutouts, or otherfeatures which can be reflected by complimentary shapes of the borderportion 660 and the insulated portion 661. Similar to the insulationbatt 220, the insulation batt 620 can also define one or more grooves760 (as shown in FIG. 7B) configured to enhance flexibility of theinsulated blank 610.

In other aspects, the insulated blank 610 may not comprise the borderportion 660 fully encompassing the insulated blank 610. In some aspects,some portions of the perimeter may expose an unfinished edge in whichthe insulation batt 620 is exposed. In some aspects, the insulated blank610 may not define the border portion 660 on any portion of theperimeter of the insulated blank 610, and the entire perimeter candefine an unfinished edge. In such aspects, the insulated blank 610 cancomprise pre-laminated paper and each of the sheets 632,634 can beattached in facing contact with the insulation batt 620 with, forexample and without limitation, an adhesive. In some aspects in whichthe insulated blank 610 defines the border portion 660, the insulationbatt 620 can also be attached in facing contact with one or both of thesheets 632,634. In some aspects, the pre-laminated paper can be providedin a roll, and the insulated blanks 610 can be cut to size from theroll.

FIG. 7A-D show top views of aspects of a blank sheet 711 and variousaspects of an insulation batt 720. FIG. 7A is a top view of the blanksheet 711. The blank sheet 711 can be, for instance, the first sheet 132or the second sheet 134 of the insulated bag 110. The blank sheet 711defines a top border portion 727, a body portion 791, a bottom portion792, a first end border portion 723, a second end border portion 728,and a bottom border portion 705. The blank sheet 711 can further definea plurality of crease lines 716,722,741 which can correspond to the sidecrease lines 116, the main crease lines 122, and the bottom crease lines441, respectively. The top border portion 727 can extend across theblank sheet 711 from a first end 724 to a second end 725 and define awidth W_(A). The top border portion 727 can define a height H_(A). Inthe aspect shown, the top border portion 727 can be extended, and theheight H_(A) is be larger than a height H_(D) defined by the bottomborder portion 705. In such aspects, the top border portion 727 can be auninsulated lip portion 726. For example and without limitation, theheight H_(A) can be greater than 1″, and the height H_(D) can be equalto or less than 1″. The first end border portion 723 and the second endborder portion 728 can each define a width W_(F) which can have a valuesimilar to height H_(D) of the bottom border portion 705.

An extended top border portion 736 can be desirable for aspects in whichthe corresponding insulation batt 720 is thick and less flexible or inapplications in which the corresponding uninsulated bag lip 136 can beconfigured to seal the bag opening 131 as shown in FIG. 5C, 5D, or 5F.Such aspects can benefit from the increased flexibility which can beoffered by the extended uninsulated bag lip 136.

The body portion 791 can extend from the first end 724 to the second end725, also defining the width W_(A). The top border portion 736 and thebody portion 791 can together define a pair of side portions 714 and apair of main portions 712 which can correspond to the side panels 114and the main panels 112 of the insulated bag 110. The body portion 791can define a height H_(B) and is positioned between the top borderportion 736 and the bottom portion 792. The side portions 714 can definea width W_(B), and the main portions 712 can define a width W_(C). Inthe present aspect, one of the main portions 712 can be positioned atthe first end 724, corresponding to the first end 124, and one of theside portions 714 can be positioned at the second end 725, correspondingto the second end 125, and the blank sheet 711 can be configured to formthe main seam 120 positioned between one of the side panels 114 and oneof the main panels 112.

The bottom portion 792 can define a height H_(C). The bottom portion 792can define a pair of bottom subpanel portions 702 and a pair of wingportions 751. The bottom subpanel portions 702 can correspond to thebottom subpanels 202, and the wing portions 751 can correspond to thewings 150. Each wing portion 751 can be divided into a pair of lowerwing portions 706 and a pair of upper wing portions 704. When assembledinto the insulated bag 110, the upper wing portions 704 can be in facingengagement with the side panels 114, and the lower wing portions 706 canface outwards from the insulated bag 110 and can be covered by the tapestrip 160.

FIG. 7B is a top view of one aspect of the insulation batt 720. Theinsulated batt 720 can define a width W_(H) and a height H_(E). Similarto the process shown in FIG. 6, the insulated batt 720 can beencapsulated between a pair of the blank sheets 711 to form theinsulated blank 111. The top border portions 727, the first end borderportions 723, the second end border portions 728, and the bottom borderportions 705 can be attached together respectively to seal the insulatedbatt 720 within a blank cavity similar to the blank cavity 670. Theinsulated batt 720 can define a thickness (not shown) which can rangefrom less than 1/16″ to over 2″. In the present aspect, the preferredthickness range can be from less than 1″ to over 1.5″. In aspects inwhich the thickness is relatively thin, such as 1/16″ to ¼″, the widthW_(H) can be substantially a value equal to the value of a width W_(K).The width W_(K) corresponds to a width of the blank sheet 711 less thewidth of the first end border portion 723 and the width of the secondend border portion 728 (width W_(A) less both the widths W_(F)). Inaspects in which the thickness is larger, such as over ½″, the widthW_(H) can be slightly smaller than the width W_(K), for example andwithout limitation 1″ less, to allow clearance within the blank cavityfor the insulation batt 720.

In the aspect shown, the height H_(E) of the insulation batt 720 can besized to cover only the body portion 791, and can be substantially thesame as or slightly less, for example and without limitation 1″ less,than the value of height H_(B) of the body portion 791. Thisconfiguration can be desirable in aspects in which the thickness of theinsulation batt 720 is greater than ½″. In such aspects, the bottompanel 201 is uninsulated and can be covered by the insulated panel 190.

Alternatively, the insulation batt 720 can be sized to cover both thebody portion 791 and the bottom portion 792, and the correspondinginsulated bag 110 can comprise insulated side panels 114, insulated mainpanels 112, insulated wings 150, and the insulated bottom panel 201. Inthis configuration, the insulated wings 150 can comprise two layers ofinsulation: a first layer corresponding to the upper wing portions 704and a second layer corresponding to the lower wing portions 706. Thefirst layer and the second layer can overlap one another when the wings150 are formed. In such aspects, the height H_(E) can have a valuesimilar or slightly less than the combined value of heights H_(B) andH_(C). This configuration can be suited for applications in which theinsulation batt 720 defines the thickness equal to ¼″ or less; however,this configuration can be used with thickness greater than ¼″.

The thickness of the insulation batt 720 can affect how flexible theinsulation batt 720 may be with greater thickness values generally beingless flexible and smaller thickness values generally being moreflexible. With greater thickness values, the insulation batt 720 can bedifficult to fold, particularly when forming the wings 150 from the wingportions 751 and when folding the bottom subpanels 202 relative to themain panels 112.

The flexibility of the insulation batts 220,391,620,720 can be increasedby modifying the insulation batts 220,391,620,720, such as by forminggrooves 760 into the insulation batt 220,391,620,720 as shown in FIG.7B. The grooves 760 can locally reduce a thickness of the insulationbatt 220,391,620,720. Each groove 760 can render the insulation batt 720more flexible when folding about the groove 760. In the present aspect,each of the grooves 760 can correspond to a different one of the maincrease lines 122. The grooves 760 can be configured to increase theflexibility between the side panels 114 and the main panels 112 of theinsulated bag 110. In some aspects, the grooves can be configured toalign with the side crease lines 116, the bottom crease lines 441, orany other crease lines defined by the insulated blank 111 or theinsulated panels 190. In some aspects, the insulation batt 720 may notdefine grooves 760. Each of the grooves 760 can be cut or shaped intothe insulation batt 220 and can reduce a thickness of the insulationbatt 220,391,620,720 at a location of the groove 760. Each groove 760can define a V-shape; however, the grooves 760 can define other shapessuch as semicircular or any other shape.

FIG. 7C is a top view of one aspect of the insulation batt 720comprising a pair of bottom subpanel extensions 732. The bottom subpanelextensions 732 can correspond to the bottom subpanel portions 702, and apair of wing notches 735 can correspond to the wing portions 751. Theinsulation batt 720 can define a width W_(I) with a value similar to orslightly less than the width W_(K). The portions of the insulated batt720 defining the bottom subpanel extensions 732 can define a heightH_(F) with a value similar to or slightly less than the combined valueof heights H_(B) and H_(C). The portions of the insulated batt 720corresponding to the wing notches 735 can define a height H_(G) with avalue equal to or slightly less than the height H_(B).

The insulated bag 110 formed from the blank sheets 711 and the insulatedbatt 720 of FIG. 7C can comprise insulated main panels 112, insulatedside panels 114, and an insulated bottom panel 201 with uninsulatedwings 150. Such a configuration can be desirable to allow for the use ofa thicker insulation batt 720 because the configuration obviates thechallenges of forming the wings 150 from the wing portions 751 when aless flexible insulation batt 720 is used, for instance. Additionally insome aspects, the insulation in the wings 150 can be unnecessary becausethe wings 150 can be secured to the outer surface 135 of the insulatedside panels 114, rendering the insulation of the wings 150 redundant toinsulation of the side panels 114.

FIG. 7D is a top view of on aspect of the insulation batt 720 defining apair of wing holes 750. The wing holes 750 can correspond to the upperwing portions 704. Alternatively, the wing holes 750 can be formed tocorrespond to the lower wing portions 706. The wing holes 750 can beformed by removing material from the insulation batt 720, such as by diecutting the insulation batt 720. In this aspect, the insulation batt 720can define a height H_(H) with a value similar to or slightly less thanthe combined value of heights H_(B) and H_(C). The insulation batt 720can define a width W_(J) with a value similar to or slightly less thanthe width W_(K). The insulated bag 110 formed from the blank sheets 711and the insulation batt 720 of FIG. 7D can comprise insulated sidepanels 114, insulated main panels 112, the insulated bottom panel 201,and wings 150 wherein only a lower portion of the wing 150 correspondingto the lower wing portions 706 is insulated. An upper portion of eachwing 150 corresponding to a one of the upper wing portions 704 can beuninsulated. Such a configuration can also be desirable for largerinsulation thicknesses as the configuration eliminates one of the layersof insulation in the wings 150 which can make the wings 150 moreflexible.

FIG. 8 is a top view of a double blank sheet 811. The double blank sheet811 can be similar to the blank sheet 711; however rather than attachinga first sheet 632 to a blank sheet 634 to form an insulated blank asshown in FIG. 6, the double blank sheet 811 is configured to fold inhalf about an axis 801 to encapsulate an insulation batt and form aninsulated blank. A secondary portion 800B is configured to fold over toattach to a primary portion 800A. Once folded, a pair of first endportions 824A,B can define a first end (not shown) at a crease line 803,and a pair of second end portions 825A,B can be attached to form asecond end (not shown). The primary portion 800A and the secondaryportion 800B of the double blank sheet 811 can be substantially mirroredacross the axis 801. A pair of primary side panel portions 814A and apair of primary main panels 812A are configured to align with a pair ofsecondary side panel portions 814B and a pair of secondary main panels812B, respectively, when the double blank sheet 811 is folded in half atthe crease line 802. Similarly, a pair of primary bottom subpanelportions 802A and a pair of primary wing portions 850A are configured toalign with a pair of second bottom subpanel portions 802B and a pair ofsecondary wing portions 850B, respectively, when the double blank sheet811 is folded in half at the crease line 803.

Once folded, a primary top border portion 836A can be attached in facingengagement with a secondary uninsulated lip portion 836B, a primarysecond end border portion 826A can be attached in facing engagement witha secondary second end border portion 826B, and a primary bottom borderportion 805A can be attached in facing engagement with a secondarybottom border portion 805B in order to form a blank cavity configured toencapsulate an insulation batt 720 aspects shown in FIGS. 7B-D, byplacing the insulation batt 720 on the corresponding portions of theprimary portion 800A and then folding the double blank sheet about thecrease line 803 to encapsulate the insulation batt 720.

FIG. 9 is a perspective view of a method of assembling one aspect of aninsulated bag 910 comprising flaps 510. In a step 901, an insulatedblank 911 lays in an unfolded position. The insulated blank 911 can besimilar in composition and construction to the insulated blank 610 witha plurality of slots cuts 909 and a pair of end cuts 912 defined intothe insulated blank 610. The slot cuts 909 can be defined into a topblank end 926 to form a first plurality of flaps 510 which can be aplurality of top flaps 904A,B. A pair of top flaps 904A can beconfigured to oppose each other in an assembled configuration shown instep 903, and a pair of top flaps 904B can be configured to oppose eachother in the assembled configuration. The slot cuts 909 can be definedinto a bottom blank end 928 to form a second plurality of flaps 510which can be a plurality of bottom flaps 905A,B. A pair of bottom flaps905A can be configured to oppose each other in the assembledconfiguration, and a pair of bottom flaps 905B can be configured tooppose each other in the assembled configuration.

A body portion 931 can extend from a first end 924 to a second end 925of the insulated blank 911, between the top flaps 904 and the bottomflaps 905. A pair of main crease lines 933 can extend between the bodyportion 931 and the top flaps 904 and between the body portion 931 andthe bottom flaps 905. A plurality of side crease lines 932 can bedefined extending between aligned slots cuts of the top blank end 926and the bottom blank end 928. The insulated blank 911 can also definethe pair of end cuts 912 at the first end 924 of the insulated blank911. The end cuts 912 can define an end connection tab 927, and an endcrease line 930 can be defined extending between the end cuts 912.

Each slot cut 909 and end cut 912 can extend through a top sheet, abottom sheet, and an insulation batt 920 of the insulated blank 911. Inthe aspect shown, the insulation batt 920 can be exposed at some or allof the slot cuts 909 and the end cuts 912. In other aspects, a blankborder 940 can be shaped complimentary to the slots cuts 909 and the endcuts 912, and the blank border 940 can fully enclose the insulation batt920.

In a step 902 of the method, the insulated blank 911 can be folded alongeach of the side crease lines 932 and the end crease line 930 to alignthe end connection tab 927 of the first end 924 with the second end 925of the insulated blank 911. In the present aspect, the end connectiontab 927 can comprise the adhesive strip 460 which can be configured toattach the first end 924 to the second end 925, thereby forming a bagbody 950. The top blank end 926 and the bottom blank end 928 of theinsulated bag 910 can remain open at step 902.

In a step 903 of the method, the bottom blank end 928 can be sealed byfolding a first pair of opposing bottom flaps 905A towards the bag body950 formed by the body portion 931, and then folding a second pair ofopposing bottom flaps 905B towards the bag body 950 to overlap the firstopposing bottom flaps 905A. The bottom flaps 905 can then be secured inplace with a tape strip 960. The top blank end 926 can similarly besealed by folding a first pair of opposing top flaps 904A towards thebag body 950, and then folding a second pair of opposing top flaps 904Btowards the bag body 950 to overlap the first opposing top flaps 904A.

In the present aspect, the sheets 132,134,332,334,634,634,711,811 cancomprise paper, such as kraft paper; however, in other embodiments, thesheets can comprise posterboard, cardboard, plastic sheeting, cloth, orany other suitable material. In some aspects, the sheets can comprise awater-proof or water-resistant material, such as water-proof paper. Insome aspects, a one of the sheets 132,134,332,334,634,634,711,811 of theinsulated bag assembly 100 can comprised a material different fromanother of the sheets 132,134,332,334,634,634,711,811. The insulationbatts 220,391,620,720 can comprise paper or other paper fiber materials;however, in other aspects, the insulation batts can comprise cotton,foam, rubber, plastics, fiberglass, mineral wool, or any other flexibleinsulation material. In the present application, the insulation battscan be repulpable. In the present aspect, the insulated bag assembly 100can be 100% recyclable. In the present aspect, the insulated bagassembly 100 can be single-stream recyclable wherein all materialscomprised by the insulated bag assembly 100 can be recycled by a singleprocessing train without requiring separation of any materials orcomponents of the insulated bag assembly 100. In the present aspect, theinsulated bag assembly 100 can be compostable. In the present aspect,the insulated bag assembly 100 can be repulpable. In the present aspect,insulated bag assembly 100 and each of the insulated bag 110 and theinsulated panels 190 can be repulpable in accordance with therequirements of the Aug. 16, 2013, revision of the “Voluntary StandardFor Repulping and Recycling Corrugated Fiberboard Treated to Improve ItsPerformance in the Presence of Water and Water Vapor” provided by theFibre Box Association of Elk Grove Village, Ill. which is herebyincorporated in its entirety. In the present aspect, insulated bagassembly 100 and each of the insulated bag 110 and the insulated panels190 can be recyclable in accordance with the requirements of the Aug.16, 2013, revision of the “Voluntary Standard For Repulping andRecycling Corrugated Fiberboard Treated to Improve Its Performance inthe Presence of Water and Water Vapor” provided by the Fibre BoxAssociation of Elk Grove Village, Ill.

Recyclable and repulpable insulation materials are further described inU.S. Patent Application No. 62/375,555, filed Aug. 16, 2016, U.S. PatentApplication No. 62/419,894, filed Nov. 9, 2016, and U.S. PatentApplication No. 62/437,365, filed Dec. 21, 2016, which are eachincorporated by reference in their entirety herein.

The insulated bag assembly 100 can be used in applications in which auser or mail carrier transports perishable or temperature-sensitivegoods. For example and without limitation, the insulated bag assembly100 can be used to transport groceries. The insulated bag assembly 100can improve upon a common plastic grocery bag by providing insulation toprevent spoilage of the contents.

Common plastic grocery bags are not accepted by many recyclingfacilities or curb-side recycling programs in which a waste managementservice collects recyclables at a user's home. Consequently, many commonplastic grocery bags are deposited in landfills where the plasticgrocery bags decompose very slowly, sometimes over the course of severalcenturies. In some instances, plastic grocery bags can enter the oceanswhere the plastic grocery bags can remain for years and harm marinelife. In some aspects, the insulated bag assembly 100 can reduce wasteand pollution by comprising materials which are recyclable orbiodegradable. In aspects in which the insulated bag assembly 100 iscurb-side or single-stream recyclable, the user may be more likely torecycle the insulated bag assembly 100 due to the ease of curb-sidecollection.

A method for assembling an insulated bag 110 can comprise folding afirst main panel 112 of a pair of opposing main panels 112 relative to afirst side panel 114 of a pair of opposing side panels 114 about a maincrease line 122. The main panels 112, the side panels 114, and the maincrease line 122 can be defined in an insulated blank 111. The insulatedblank 111 can comprise an insulation batt 220, a first sheet 132, and asecond sheet 134. The insulation batt 220 can be encapsulated in a blankcavity 221 defined between the first sheet 132 and the second sheet 134.A blank border 440 can extend around a perimeter of the insulated blank111. The blank border 440 can be defined by a perimeter portion of thefirst sheet 132 being in facing engagement with a perimeter portion ofthe second sheet 134. The blank border 440 can encompass the blankcavity 221 and define an insulated portion of the insulated blank 111.The insulated blank 111 can define a first end 124 and a second end 125.The first end 124 can be disposed opposite from the second end 125.

The first end 124 can be attached to the second end 125 which can form abag body 101. The first end 124 can be attached to the second end 125 byforming a main seam 120 between a one of the main panels 112 and a oneof the side panels 114. The bag body 101 can be defined by the mainpanels 112 and the side panels 114. The bag body 101 can define arectangular cross-sectional shape. A bottom panel 201 of the insulatedbag 110 can be formed by folding a portion of the bottom panel 201relative to the main panel 112 about a bottom crease line 441. Theportion of the bottom panel 201 can be a bottom subpanel 202. The bottompanel 201 can comprise a pair of bottom subpanels 202. Each bottomsubpanel 202 can be attached to a different one of the main panels 112.Forming the bottom panel 201 can comprise attaching a first bottomsubpanel of the pair of bottom subpanels 202 to a second bottom subpanelof the pair of bottom subpanels 202. The bottom panel 201 and the bottomcrease line 441 can be defined by the insulated blank 111.

One should note that conditional language, such as, among others, “can,”“could,” “might,” or “may,” unless specifically stated otherwise, orotherwise understood within the context as used, is generally intendedto convey that certain embodiments include, while other embodiments donot include, certain features, elements and/or steps. Thus, suchconditional language is not generally intended to imply that features,elements and/or steps are in any way required for one or more particularembodiments or that one or more particular embodiments necessarilyinclude logic for deciding, with or without user input or prompting,whether these features, elements and/or steps are included or are to beperformed in any particular embodiment.

It should be emphasized that the above-described embodiments are merelypossible examples of implementations, merely set forth for a clearunderstanding of the principles of the present disclosure. Any processdescriptions or blocks in flow diagrams should be understood asrepresenting modules, segments, or portions of code which include one ormore executable instructions for implementing specific logical functionsor steps in the process, and alternate implementations are included inwhich functions may not be included or executed at all, may be executedout of order from that shown or discussed, including substantiallyconcurrently or in reverse order, depending on the functionalityinvolved, as would be understood by those reasonably skilled in the artof the present disclosure. Many variations and modifications may be madeto the above-described embodiment(s) without departing substantiallyfrom the spirit and principles of the present disclosure. Further, thescope of the present disclosure is intended to cover any and allcombinations and sub-combinations of all elements, features, and aspectsdiscussed above. All such modifications and variations are intended tobe included herein within the scope of the present disclosure, and allpossible claims to individual aspects or combinations of elements orsteps are intended to be supported by the present disclosure.

That which is claimed is:
 1. An insulated bag assembly comprising: aninsulated bag, the insulated bag comprising a pair of opposing mainpanels, the main panels defined in an insulated blank, the insulatedblank comprising an insulation batt, a first sheet, and a second sheet,the insulation batt encapsulated in a blank cavity defined between thefirst sheet and the second sheet, a blank border extending around aperimeter of the insulated blank, the blank border defined by aperimeter portion of the first sheet being in facing engagement with aperimeter portion of the second sheet, the blank border encompassing theblank cavity and defining an insulated portion of the insulated blank,the insulated bag defining a top end and a bottom end, the top enddistal from the bottom end, the insulated bag defining a bag cavity witha bag opening positioned at the top end; and an insulated panel, theinsulated panel positioned within the bag cavity, the insulated panelforming a seal with the insulated bag.
 2. The insulated bag assembly ofclaim 1, wherein: the insulated bag defines a bag beveled edge proximatethe bag opening; the insulated panel defines a panel beveled edge; andthe bag beveled edge and the panel beveled edge are configured tocooperate to form the seal.
 3. The insulated bag assembly of claim 1,wherein: the insulated panel is a first insulated panel; the insulatedbag assembly further comprises a second insulated panel; the firstinsulated panel forms the seal proximate the bag opening; the secondinsulated panel is positioned within the bag cavity between the top endand the bottom end; and the second insulated panel partitions the bagcavity into two subcavities.
 4. The insulated bag assembly of claim 1,wherein: the insulated bag comprises a bottom panel disposed at thebottom end; and the insulated panel is positioned atop the bottom panelat the bottom end of the insulated bag.
 5. The insulated bag assembly ofclaim 1, wherein the blank border at the top end extends outwards fromthe insulated blank further than the blank border at the bottom end. 6.The insulated bag assembly of claim 1, wherein the blank border extendsfrom the top end to the bottom end of the insulated bag.
 7. Theinsulated bag assembly of claim 1, wherein the main panels of theinsulated bag are defined by the insulated portion of the insulatedblank.
 8. An insulated bag comprising: a pair of opposing main panels,the insulated bag defining a bag cavity within the insulated bag, theinsulated bag defining a bag opening to the bag cavity, the bag openingdisposed at a top end of the insulated bag; the main panels defined inan insulated blank, the insulated blank comprising: a first sheet; asecond sheet, the second sheet attached to the first sheet by a blankborder, the blank border extending around a perimeter of the insulatedblank, the blank border enclosing a blank cavity defined between thefirst sheet and the second sheet; and an insulation batt positionedwithin the blank cavity.
 9. The insulated bag of claim 8, wherein: theinsulated bag further comprises: a pair of opposing side panels, each ofthe side panels attached to both of the pair of main panels, the pair ofside panels further defining the bag cavity and the bag opening; and abottom panel, the bottom panel positioned at a bottom end of theinsulated bag and further defining the bag cavity, the bottom enddisposed opposite from the top end, the bottom panel attached to each ofthe main panels; and the side panels and the bottom panel are defined inthe insulated blank.
 10. The insulated bag of claim 8, wherein: theinsulated blank defines a first end and a second end; the first end isdefined opposite from the second end; and the first end is attached tothe second end by a main seam.
 11. The insulated bag of claim 10,wherein: the insulated bag further comprises a pair of side panels; themain seam is defined between a one of the main panels and a one of thepair of side panels; and the main seam attaches the one of the mainpanels to the one of the side panels.
 12. The insulated bag of claim 11,wherein: the main seam is defined by a portion of the blank border; theblank border extends from the top end to a bottom end; and the main seamis a four-ply seam.
 13. The insulated bag of claim 8, wherein theinsulation batt is a single, continuous piece of insulation extendingthrough the main panels.
 14. The insulated bag of claim 8, wherein agroove is formed into the insulation batt, and the groove is configuredto increase flexibility of the insulation batt when the insulation battis folded about the groove.
 15. The insulated bag of claim 8, whereinthe insulated bag further comprises a handle attached proximate the topend of the insulated bag.
 16. A method for assembling an insulated bagcomprising: folding a first main panel of a pair of opposing main panelsrelative to a first side panel of a pair of opposing side panels about amain crease line, the main panels, the side panels, and the main creaseline defined in an insulated blank, the insulated blank comprising aninsulation batt, a first sheet, and a second sheet, the insulation battencapsulated in a blank cavity defined between the first sheet and thesecond sheet, a blank border extending around a perimeter of theinsulated blank, the blank border defined by a perimeter portion of thefirst sheet being in facing engagement with a perimeter portion of thesecond sheet, the blank border encompassing the blank cavity anddefining an insulated portion of the insulated blank, the insulatedblank defining a first end and a second end, the first end disposedopposite from the second end; attaching the first end to the second end;and forming a bottom panel of the insulated bag by folding a portion ofthe bottom panel relative to the main panel about a bottom crease line,the bottom panel and the bottom crease line further defined by theinsulated blank.
 17. The method of claim 16, wherein attaching the firstend to the second end forms a bag body, wherein the bag body is definedby the main panels and the side panels, and wherein the bag body definesa rectangular cross-section.
 18. The method of claim 16, wherein thebottom panel comprises a pair of bottom subpanels, wherein each bottomsubpanel is attached to a different one of the main panels, and whereinforming the bottom panel further comprises attaching a first bottomsubpanel of the pair of bottom subpanels to a second bottom subpanel ofthe pair of bottom subpanels.
 19. The method of claim 16, whereinattaching the first end to the second end further comprises forming amain seam between a one of the main panels and a one of the side panels.20. The method of claim 16, wherein: the bottom panel comprises fourbottom flaps; each of a first pair of the four bottom flaps is attachedto a different one of the side panels; each of a second pair of the fourbottom flaps is attached to a different one of the main panels; andforming the bottom panel further comprises overlapping a first bottomflap of the first pair of bottom flaps with a first bottom flap of thesecond pair of bottom flaps.